MULTI-COIL SPARK IGNITION SYSTEM
An igniter for a spark ignition system includes a support body fabricated from an electrically insulating material and a metal casing disposed outwardly of and at least partially surrounding the support body. The metal casing has a structure for connecting the metal casing to ground. At least two rod-shaped first electrodes are supported one relative to another by the support body and are electrically isolated one from the other by the support body. Each first electrode has a first end that protrudes from a first end of the support body at a spark forming end of the igniter. The support body is disposed at least partly within an axial channel of a generally cylindrically-shaped second electrode. The second electrode projects past the support body at the spark forming end of the igniter and cooperates with the first ends of the at least two first electrodes to define at least two spark gaps. The second electrode is electrically isolated from the metal casing by an air gap. During use the first electrodes receive a first voltage that is higher than ground and the second electrode receives a second voltage that is lower than the first voltage. A first spark is formed within a first one of the at least two spark gaps and a second spark is formed within a second one of the at least two spark gaps.
This application is a division of U.S. patent application Ser. No. 13/917,054 filed on Jun. 13, 2013, which claims priority from U.S. Provisional Application 61/702,469 filed on Sep. 18, 2012 and incorporates the disclosure of each application in their entirety by reference.
FIELD OF THE INVENTIONThe present invention relates generally to spark ignition systems. More particularly, the present invention relates to multi-coil spark ignition systems for internal combustion engines and to methods for generating multiple sparks at one spark event and/or for controlling spark events based on feedback signals.
BACKGROUND OF THE INVENTIONIn a spark ignition system an igniter, such as for instance a spark plug, is used to ignite an air-fuel mixture within a combustion zone. It is desirable to dilute the combustible mixture by increasing the air/fuel ratio, or by increasing the level of exhaust gas recirculation (EGR), which enables operation at higher compression ratios and loads and achieves cleaner and more efficient combustion. Unfortunately, operation at these increased dilution levels gives rise to problems relating to both ignition and flame propagation, necessitating the use of a robust ignition source to ensure successful ignition and stable combustion.
Additional problems are encountered in engines that have a stratified in-cylinder charge and strong charge motion. Under such conditions a long sparking duration is used so as to increase the probability of catching the optimum mixture pocket near the igniter, thereby improving ignition reliability. It has been reported that a longer duration spark with low peak current has better ignition properties than a shorter duration spark with higher peak current under the enhanced charge motion condition.
It would be beneficial to provide a spark ignition system and related methods that achieve reliable combustion results at lean and/or EGR cylinder charges below the limits that are currently encountered.
SUMMARY OF THE INVENTIONIn accordance with an aspect of the invention, a spark ignition system is provided comprising igniters (e.g., spark plugs) with plural high-voltage (HV) electrodes, either positive or negative. The spark ignition system further comprises a coil assembly having plural ignition coils to manage the spark discharge process, and multiple isolated high-tension cables to deliver energy from the ignition coils to the igniter. The spark ignition system is suitable for improving ignition quality by using one or more of the following approaches:
1) Enlarge the spark kernel.
2) Provide multiple discharge channels.
3) Prolong the discharge duration.
4) Generate turbulence around the spark gap to promote the combustion speed at the early stage of combustion.
5) Produce radical species to promote chemical reaction at the early stage of combustion.
In accordance with an aspect of an embodiment of the invention, there is provided an ignition system for an internal combustion engine, comprising: an igniter having at least two high voltage (HV) electrodes and a low voltage (LV) electrode, the at least two HV electrodes being electrically isolated one from the other and the at least two HV electrodes being electrically isolated from the LV electrode; a coil assembly having at least one primary winding and at least two secondary windings, each secondary winding having a terminal for providing a HV signal; a driver module for energizing the coil assembly; and a high tension cable comprising at least two resistive wires, each one of the at least two resistive wires connecting one of the at least two HV electrodes to the terminal of one of the at least two secondary windings, and the high tension cable further comprising a non-resistive wire connecting the LV electrode to the driver module.
In accordance with an aspect of an embodiment of the invention, there is provided a method, comprising: providing an ignitable fuel mixture in a combustion zone; providing a multi-electrode igniter in communication with the combustion zone, the multi-electrode igniter comprising at least two high voltage (HV) electrodes and a low voltage (LV) electrode, each one of the at least two HV electrodes connected to a different secondary winding of a coil assembly; using a driver module, energizing and discharging the coil assembly to provide an HV signal to each one of the at least two HV electrodes; producing a plurality of sparks within the combustion zone based on the HV signals that are sent to each one of the at least two HV electrodes; generating a feedback signal based on at least one of a sensed spark discharge current and a sensed combustion ion current within the combustion zone; providing the feedback signal to a feedback circuit of the driver module; and based on the feedback signal, adjusting a parameter for energizing and discharging of the coil assembly.
In accordance with an aspect of an embodiment of the invention, there is provided an igniter for a spark ignition system, comprising: a support body fabricated from an electrically insulating material; a metal casing disposed outwardly of and at least partially surrounding the support body, the metal casing having a structure for connecting the metal casing to ground; at least two rod-shaped high voltage (HV) electrodes supported one relative to another by the support body and electrically isolated one from the other by the support body, each HV electrode of the at least two HV electrodes having a first end that protrudes from a first end of the support body at a spark forming end of the igniter; and a generally cylindrically-shaped low voltage (LV) electrode having an axial channel, the support body being disposed at least partly within the axial channel, the LV electrode projecting past the support body at the spark forming end of the igniter and cooperating with the first ends of the at least two HV electrodes to define at least two spark gaps, the LV electrode further being electrically isolated from the metal casing by an air gap; wherein during use a first spark is formed within a first one of the at least two spark gaps and a second spark is formed within a second one of the at least two spark gaps.
In accordance with an aspect of an embodiment of the invention, there is provided an igniter for a spark ignition system, comprising: a support body fabricated from an electrically insulating material; a metal casing disposed outwardly of and at least partially surrounding the support body, the metal casing having a structure for connecting the metal casing to ground; at least two high voltage (HV) electrodes and a low voltage (LV) electrode, the at least two HV electrodes being electrically isolated one from the other and from the LV electrode, each one of the at least two HV electrodes and the LV electrode being a generally rod-shaped electrode supported by the support body and each one of the at least two HV electrodes and the LV electrode having a first end that protrudes from the support body at the spark forming end of the igniter, wherein the at least two HV electrodes and the LV electrode are disposed one relative to another and protrude from the support body by a distance that is sufficient to form, during a spark event, a plurality of sparks there between. The HV and LV electrodes are bonded to the support body with sufficient mechanical strength to withstand the high pressure in the combustion zone.
In accordance with an aspect of an embodiment of the invention, there is provided an igniter for a spark ignition system, comprising: a support body fabricated from an electrically insulating material; a metal casing disposed outwardly of and at least partially surrounding the support body, the metal casing having a structure for connecting the metal casing to ground; at least two rod-shaped first electrodes supported one relative to another by the support body and electrically isolated one from the other by the support body, each first electrode of the at least two first electrodes having a first end that protrudes from a first end of the support body at a spark forming end of the igniter; and a generally cylindrically-shaped second electrode having an axial channel, the support body being disposed at least partly within the axial channel, the second electrode projecting past the support body at the spark forming end of the igniter and cooperating with the first ends of the at least two first electrodes to define at least two spark gaps, the second electrode further being electrically isolated from the metal casing by an air gap; wherein during use the first electrodes receive a first voltage that is higher than ground and the second electrode receives a second voltage that is lower than the first voltage; and wherein during use a first spark is formed within a first one of the at least two spark gaps and a second spark is formed within a second one of the at least two spark gaps.
In accordance with an aspect of an embodiment of the invention, there is provided an igniter for a spark ignition system, comprising: a support body fabricated from an electrically insulating material; a metal casing disposed outwardly of and at least partially surrounding the support body, the metal casing having a structure for connecting the metal casing to ground; at least two first electrodes and a second electrode, the at least two first electrodes being electrically isolated one from the other and from the second electrode, each one of the at least two first electrodes and the second electrode being a generally rod-shaped electrode supported by the support body and each one of the at least two first electrodes and the second electrode having a first end that protrudes from the support body at the spark forming end of the igniter, wherein during use the first electrodes receive a first voltage that is higher than ground and the second electrode receives a second voltage that is lower than the first voltage; and wherein the at least two first electrodes and the second electrode are disposed one relative to another and protrude from the support body by a distance that is sufficient to form, during a spark event, a plurality of sparks therebetween.
The instant invention will now be described by way of example only, and with reference to the attached drawings, wherein similar reference numerals denote similar elements throughout the several views, and in which:
The following description is presented to enable a person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the scope of the invention. Thus, the present invention is not intended to be limited to the embodiments disclosed, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
Each one of the first and second HV electrodes 102 and 104 is connected to a separate secondary winding (not shown in
In the specific and non-limiting example that is shown in
Referring now to
Referring now to
Referring now to
Referring also to
-
- two or more of the HV electrodes and the LV electrode, and/or
- two of the HV electrodes and at least one of the HV electrodes and the LV electrode.
Depicted in
In
When the coils 700 and 702 are parallel connected, the two coils can be driven by one driver module with a single command signal. Alternatively, as shown in
The ignition systems that are described in the preceding paragraphs, in particular with reference to
Referring now to
The feedback currents are sensed using LV electrode 108, and provide a feedback signal that may be used as an input to a control algorithm implemented by the driver module 116. The spark discharge current is fed back for use in detecting spark malfunctions such as insufficient current delivery and spark blow-off etc., providing information of air/fuel ratio and gas motion. The duration of spark current, peak of spark current, and the first or/and the second order differential of spark current profile are calculated from the sensed spark current signal. Based on pre-calibrated correlations between the spark current parameters and the mixture parameters, information of gas motion, air/fuel mixture strength can be obtained, providing a database for decision making of driver module 116. The combustion ion current is fed back for use in diagnosing combustion processes, and detecting misfire, etc.
In the ignition systems that are described above, in order to prevent breakdown between the HV electrodes the design parameters for each HV electrode and the attached high voltage cable and ignition coil should be substantially identical. For instance, the coil specifications, the length and the impedance of the high voltage cable, and the gap size between the HV electrodes and the low voltage electrode should be substantially identical.
Of course, the ignition systems and igniters that are described above with reference to
While the above description constitutes a plurality of embodiments of the invention, it will be appreciated that the present invention is susceptible to further modification and change without departing from the fair meaning of the accompanying claims.
Claims
1. An igniter for a spark ignition system, comprising:
- a support body fabricated from an electrically insulating material;
- a metal casing disposed outwardly of and at least partially surrounding the support body, the metal casing having a structure for connecting the metal casing to ground;
- at least two rod-shaped first electrodes supported one relative to another by the support body and electrically isolated one from the other by the support body, each first electrode of the at least two first electrodes having a first end that protrudes from a first end of the support body at a spark forming end of the igniter; and
- a generally cylindrically-shaped second electrode having an axial channel, the support body being disposed at least partly within the axial channel, the second electrode projecting past the support body at the spark forming end of the igniter and cooperating with the first ends of the at least two first electrodes to define at least two spark gaps, the second electrode further being electrically isolated from the metal casing by an air gap;
- wherein during use the first electrodes receive a first voltage that is higher than ground and the second electrode receives a second voltage that is lower than the first voltage; and
- wherein during use a first spark is formed within a first one of the at least two spark gaps and a second spark is formed within a second one of the at least two spark gaps.
2. The igniter according to claim 1 wherein the structure for connecting the metal casing to ground comprises an external thread for mating with an internal thread of an engine cylinder block.
3. The igniter according to claim 1 wherein slots are defined through portions of the second electrode, and wherein the support body extends through the slots and forms a ring portion that encircles the second electrode, the ring portion engaging a shoulder feature along an inner surface of the metal casing.
4. The igniter according to claim 2 wherein the support body comprises a first generally cylindrical portion extending between the ring portion and the first end of the support body and a second generally cylindrical portion extending between the ring portion and a second end of the support body that is opposite the first end, the diameter of the second generally cylindrical portion larger than the diameter of the first generally cylindrical portion.
5. The igniter according to claim 4 wherein the air gap is a generally annular space that is formed between the metal casing and the first generally cylindrical portion of the support body.
6. The igniter according to claim 4 wherein the second electrode is embedded within the second generally cylindrical portion of the support body.
7. The igniter according to claim 24 comprising a sealant material disposed between the ring portion of the support body and the metal casing, the sealant material forming a gas tight seal at one end of the air gap.
8. An igniter for a spark ignition system, comprising:
- a support body fabricated from an electrically insulating material;
- a metal casing disposed outwardly of and at least partially surrounding the support body, the metal casing having a structure for connecting the metal casing to ground;
- at least two first electrodes and a second electrode, the at least two first electrodes being electrically isolated one from the other and from the second electrode, each one of the at least two first electrodes and the second electrode being a generally rod-shaped electrode supported by the support body and each one of the at least two first electrodes and the second electrode having a first end that protrudes from the support body at the spark forming end of the igniter,
- wherein during use the first electrodes receive a first voltage that is higher than ground and the second electrode receives a second voltage that is lower than the first voltage; and
- wherein the at least two first electrodes and the second electrode are disposed one relative to another and protrude from the support body by a distance that is sufficient to form, during a spark event, a plurality of sparks therebetween.
9. The igniter according to claim 8 wherein the at least two first electrodes are disposed relative to one another and relative to the second electrode, such that during use a first spark is formed between the first end of a first one of the at least two first electrodes and the first end of the second electrode, and such that during use a second spark is formed between the first end of a second one of the at least two first electrodes and the first end of the second electrode.
10. The igniter according to claim 8 wherein the at least two first electrodes are disposed relative to one another and relative to the second electrode, such that during use a first spark is formed between the first end of a first one of the at least two first electrodes and the first end of a second one of the at least two first electrodes, and such that a second spark is formed between the first end of the second one of the at least two first electrodes and the first end of the second electrode.
11. The igniter according to claim 8 wherein the second electrode is disposed approximately centrally with respect to a symmetrical arrangement of the at least two first electrodes.
12. The igniter according to claim 8 wherein the at least two first electrodes are disposed along two orthogonal lines, the two orthogonal lines intersecting approximately at the center of the first end of the second electrode.
13. The igniter according to claim 12 wherein plural first electrodes are disposed along each of the two orthogonal lines on each opposite side of the second electrode, such that during use first sparks are formed between outer and inner first electrodes and second sparks are formed between inner first electrodes and the second electrode.
14. The igniter according to claim 8 wherein the second electrode is disposed other than approximately centrally with respect to an arrangement of the at least two first electrodes.
15. The igniter according to claim 8 wherein the second electrode is disposed relative to the at least two first electrodes such that during use a first spark is formed between a first one of the at least two first electrodes and a second one of the at least two first electrodes and a second spark is formed between the second one of the at least two first electrodes and the second electrode.
16. The igniter according to claim 8 wherein the at least two first electrodes and the second electrode are disposed along a curved line and the second electrode is disposed at one end of the curved line, such that during use a spark is formed between each pair of adjacent first electrodes in the line and between the second electrode and the one of the first electrodes that is closest thereto.
17. The igniter according to claim 16 wherein the curved line forms a part of a spiral.
Type: Application
Filed: Aug 17, 2016
Publication Date: Dec 8, 2016
Patent Grant number: 10054099
Inventor: Ming ZHENG (Windsor)
Application Number: 15/238,886